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E Instruments BTU1100 Combustion Gas Analyzer User Manual

1. DELETE SINGLE DELETE SINGLE Save analysis I WARNING 4 WARNING Display average Delete all data Delete all data Select memory in the memory 01 in the memory 01 Recall memory gt Delete single x QUIT DELETE QUIT DELETE DELETE SINGLE WARNING Delete all data in the memory 01 Please wait DELETE ALL DELETE ALL a Display average L WARNING WARNING Select memory Delete all data Delete all data Recall memory in all memories in all memories Delete single gt Delete all QUIT DELETE QUIT 22 DELETE ALL WARNING Delete all data in all memories Please wait 4 5 Print Menu A This menu is used to access the following print and check configurations Print analysis report Shows the details of the selected ticket type and allows the analyzer to print Configure Print Allows the user to set the number of printed copies and layout of the ticket The ticket layout selection is only valid for combustion analysis and can be chosen among Complete Partial and Total Tickets for draft smoke ambient gas concentration and tightness test only allow a specific layout Layouts for combustion analysis are specified as described in the following Full Includes a header with company data as well operator data previously programmed in the configuration menu measurements sampled in the combustion analysis and when sampled the draft smoke and CO NO ambient gas values Partial Only reports
2. Blackened particulate filter 5 6 Life of O CO and NO sensors The gas sensors used in this instrument are electrochemical thus when the relative gas is detected a chemical reaction taxes place inside them that generates an electrical current The electrical current acquired by the instrument is then converted into the corresponding gas concentration Sensor life is strongly related to the consumption of the reagents within Sensor characteristics diminish as the reagents are consumed and vvhen these have been used up completely the sensor must be replaced The sensors must be recalibrated on a regular basis to assure measuring accuracy recalibration can only be performed by a qualified E INSTRUMENTS service center Chart 5 7 illustrates the characteristics inherent to each sensor 5 7 Gas sensor life SENSOR AVERAGE LIFE RECALIBRATION TYPE ya 18 months not necessary AAC SE 01 Oxygen eo 3 years Yearly AAC SE 02 Carbon Monoxide NO Nitrogen oxide 3 years yearly AAC SE 03 1 In case the instrument is used for personal safety a recalibration performed every 6 months is highly suggested 5 8 Replacing the O CO and NO sensors The instrument s gas sensors need to be replaced periodically with new or recalibrated sensors see chart below The sensors can be easily replaced by the user as instructed below 1 Loosen the two screws and remove the rear flap to access the sensor compartment Fig 1 2
3. The values that can be selected with the Y A keys for this parameter are CO CO sv NO NO sv O P Tg Ta The values that can be selected with the Y di keys for this parameter are maximum minimum no 17 Number Measure no 100134 0000 ppm The alarm threshold values can be set via the y ds keys within the following range 99999 999 to 99999 99 the value is referred to the unit of measurement set maximum minimum no The values that can be selected with the keys for this parameter are dl ppm mg m mg kWh 8 GJ g m g kWh CONFIGURATION a Automatic analysis Condensation Time Date Alarms gt Autozero Pump v AUTOZERO PUMP AUTOZERO PUMP pAutozero Autozero Pump Pump AUTOZERO PUMP AUTOZERO PUMP Autozero Autozero gt Pump Pump CONFIGURATION a Condensation Time Date Alarms Autozero Pump gt Operator v OPERATOR ID TEKT EDITING John Smith Heating gt des 4 9 lt gt Of TO YZ _ GA BCDEFGHI Yz I a bedefghi OPERATOR ID TEXT EDITING gt es 4 9 lt gt is me YZ _ GA BCDEFGHI Yz I t a bedefghi OPERATOR ID TEKT EDITING 2 John Doe gt ges d Ed ore mo Y Z _ GA BCDEFGHI Yz I a bedefghi 18 AUTOZERO PUMP t Autozero go s Pump T Note The pump cannot be switched off during auto calibration If auto calibration has n
4. the printer pushbutton BE maa Mu 45 After removing the cover of the printer the analyzer will If the instrument is turned towards the operator as shown in the adjacent figure one can access compartment and Reset pushbutton Impact printer 5 0 MAINTENANCE 5 1 Routine maintenance This instrument was designed and manufactured using top guality components Proper and systematic maintenance will prevent the onset of malfunctions and will increase instrument life altogether The following basic reguisites are to be respected e Do not expose the instrument to substantial thermal shocks before use If this happens wait for the temperature to return to normal working values e Do not extract flue gas samples directly without using a particulate water trap e Do not exceed sensor overload thresholds e When the analysis is over disconnect the sample probe and let the analyzer draw fresh air for a few minutes or at least until the displayed parameters return to their original values e Clean the filter unit when necessary replacing the particulate filter and applying a jet of air to the sample probe hose to eliminate any condensate that may have formed Do not clean the instrument with abrasive cleaners thinners or other similar detergents 5 2 Preventive maintenance At least once a year send the instrument to a service center for a complete overhaul and thorough internal cleaning E INSTRUME
5. AAC BF01 AAC FA0 1 AAC NI01 AAC PB01 AAC RC01 AAC SE01 AAC SE02 AAC SE03 Sensor junction block Particulate filter Ink ribbon for printer Battery pack 5 x 6V 1800 mAh elements Paper roll for printer h 57 mm diam 40 mm Replaceable O sensor Replaceable CO H sensor 0 8000 ppm Replaceable NO NO sensor 7 2 Accessories AAC ALQ02 AAC CRO1 AAC CTO1 AAC DPO1 AAC RPO1 AAC KT02 AAC PMOL AAC SAOI AAC SA02 AAC SF11 AAC SF12 AAC SFIS AAC SF16 AAC SMOI AAC SVV02 AAC TAOI AAC UAOL 100 240V 12 VDC 2A power supply with 2 m cable Rigid plastic case Shoulder bag Deprimometer for Draft test Differential pressure kit Tightness test kit Manual pump kit for smoke measurement filters chart Air temperature probe cable length 2 m Air temperature probe cable length 3 m 180 mm sample probe with 3 m cable extended temperature range up to 1100 C 300 mm sample probe with 3 m cable extended temperature range up to 1100 C 750 mm sample probe with 3 m cable extended temperature range up to 1100 C 1000 mm sample probe with 3 m cable extended temperature range up to 1100 C Magnetic holder Configuration software kit CD PC cable Particulate water filter assembly with steel pipe and connector USB RS232 cable 7 3 Service Center E Instruments International 172 Middletown Blvd Suite B201 Langhorne PA 19047 USA Tel 215 750 1212 Fax 215 750 1399
6. E INSTRUMENTS 1100 8 2200 Portable Combustion Gas Analyzers issions yy n oe cur date YA 4 Ve nd any MO K x ponya 1 0 2 0 3 0 4 0 TABLE OF CONTENTS INTRODUCTION 1 1 General Overview of the Combustion Gas Analyzer 1 2 Configurations and Sensors TECHNICAL SPECIFICATIONS 2 1 Technical Specifications 2 2 Overview of Combustion analyzer Components 2 3 Measurement and Accuracy Ranges USING THE COMBUSTION ANALYZER 3 1 Preliminary operations 3 2 Power supply 3 2 1 Battery check and replacement 3 2 2 Use with external power pack 3 3 Connecting the sample probe OPERATION 4 1 Keypad overview 42 Info Menu 4 2 1 Flow Chart Info Menu 4 3 Configure Menu 4 3 1 Flow Chart Configure Menu 4 4 Memory Menu 4 4 1 Flow Chart Memory Menu 4 5 Print Menu 4 5 1 Flow Chart Print Menu 4 6 Analysis Menu 4 6 1 Zoom Menu 4 6 2 Flow Chart Analysis Menu 4 7 Draft Menu 4 7 1 Flow Chart Draft Menu 4 8 Readings Menu 4 8 1 Flow Chart Readings Menu 4 9 Flow Chart Configure Analysis Menu 4 10 Flow Chart Flue Gas Analysis 4 11 Flue Gas Analysis 4 11 1 Switching on the instrument and auto calibration 4 11 2 Inserting the probe inside the stack 4 11 3 Flue Gas Analysis 4 11 4 End of Analysis 4 12 Measuring the Differential Pressure optional kit 4 13 Resetting the Microprocessor 04 04 04 05 05 05 07 08 08 08 09 09 09 10 10 11 12 14 15 20 Di 23 24 25 25 26
7. gt CO sensor Serial 03379128 NO sensor Is 0 00 uA Ia 0 00 uA Calibr INO SENSOR DIAGNOSTIC 4 SENSOR DIAGNOSTIC t 02 sensor Type 5NF CO sensor Serial 03372448 PNO sensor Is 0 76 uA Calibr INFO SERVICE t E Instruments Tel 215 750 1212 Fax 215 750 1399 1100 SN 415000 Ver 1 10 13 4 3 Configure Menu This menu is used to configure the instrument s reference parameters described below Fuel Lets the user select the type of fuel to be used during analysis Units of measurement Through this submenu the user can modify the units of measurement for all the analysis parameters depending on how they are used O Reference In this mode the user can set the oxygen percentage level to which pollutant emission values detected during analysis will be referenced Display contrast The display contrast may be increased or decreased by acting on cursor keys A ie This operation may be performed even when the introductory screen is active Automatic analysis The user can set analysis mode to either manual or automatic In manual mode the user performs the three necessary analysis operations manually In automatic mode the cycle duration for each reading must also be set in this case the instrument will conduct each analysis in the specified time Printing may also be manual or automatic If auto printing is selected the instrument will automatically print the analysis report in
8. 2 2 Probe length 18 cm standard or 30 cm optional vvith 8 22 mm sampling hole adapter cone Connected to the analyzer via a 3 m rubber hose through a water separator and replaceable particulate filter pos in Fig 2 2 Measuring cells The instrument employs long lasting sensors to measure the oxygen carbon monoxide hydrogen compensated and nitrogen oxide NO content The measuring cells are electrochemical and do not reguire any maintenance Once spent the cells can be easily replaced without having to dispatch the instrument and since they are pre calibrated do not necessitate complicated calibration procedures involving the preparation of specimen mixtures E Instruments certifies the accuracy of its analyzers only following the release of a calibration certificate by its laboratory Temperature sensors Flue gas temperature is measured by means of a thermocouple inserted in the tip of the probe The thermocouple is connected to the instrument via a compensated cable pos Q in Fig 2 2 housed in a special seating in the rubber hose of the sample probe Connection to the instrument is achieved via a temperature compensated male connector The cold junction is compensated by a Pt 100 resistance thermometer which measures the temperature at the thermocouple connector The type K thermocouple nickel nickel chromium permits continuous measurements up to 800 C If special purpose probes are used the instrument is able to
9. E mail Info E Inst com http www E Inst com 54
10. WARNING To turn the instrument on off it is necessary to press and hold the On Off button for at least 2 seconds 10 4 2 Info Menu This menu provides information regarding instrument status Battery capacity Shovvs the status of the internal battery The battery charge status is shown graphically and in text as a percentage between 0 and 100 together with the battery voltage Fuel coefficients Shows the characteristic parameters for each of the fuels used in the calculation of the combustion efficiency Sensor diagnostics This displays useful information about the internal sensors and about instrument calibration The status of each of the internal gas sensors is shown allowing rapid diagnosis to be carried out if these are generating some form of error Information regarding each gas sensor is contained in the relative submenu and includes the type of sensor the serial number and the actual current measured by the instrument Info service This submenu contains details regarding the nearest service center to be contacted in the event of breakdown or maintenance The instrument model serial number and firmware version are also displayed permitting rapid product identification The Flow Chart in the following page shows how to browse through the Info Menu screens 11 4 2 1 Flow Chart Info Menu Activates the Info Menu INFORMATION y BATTERY STATUS t bBattery status Fuel parameters Bat 82 Sensors diagnost
11. a predetermined format at the end of the automatic analysis If auto printing is selected also at the end of a tightness test a report will be printed automatically Condensation The burner efficiency figure when condensation takes place is influenced by atmospheric pressure and humidity of the combustion air As the atmospheric pressure is hardly precisely known the operator is asked to enter a related parameter i e the altitude of the place above the sea level from which the pressure is then derived once the dependency from atmospheric conditions is neglected In calculations the value of 101325 Pa is assumed as atmospheric pressure at sea level Further the air relative humidity input is allowed being this calculated at the combustion air temperature as measured from the instrument in case this value is unknown the operator is recommended to enter 50 for this value Clock This allows the current time and date to be set The user can select the date and hour format either in EU European or USA American mode Alarms This submenu allows the user to set and memorize 5 alarms defining the monitored parameter for each the alarm threshold and relative unit of measurement and whether it is a low or high level alarm Low level alarms are triggered when the reading drops below the defined threshold whereas high level alarms are triggered when the reading rises above the defined threshold When an alarm threshold is crossed the instrume
12. P G Air UNI 11137 STANDARD pStart test Stabilization Piping volume WARNING Charge the pipe to the test pressure 10 00 hPa Combustible gas Test gas UNI 11137 STANDARD 10 OOnpa STABILIZATION P 10 00hPa AP1 0 01hPa Wait time 15 00 OK to proceed UNI 11137 STANDARD 10 00hPa 9 99hPa 0 01hPa Result 01 00 Automatically after 1 UNI 11137 STANDARD P 10 00hPa AP 0 01hPa Qtest 0 Odm3 h Qref 0 Odm3 h Result compliant PRINT gt Print report Print setup Paper feed Print test UNI 11137 STANDARD UNI 11137 STANDARD UNI 11137 STANDARD oe Pi O O Gnpa 0 OOnpa Pressurize the piping and select TEST with the jy key During stabilization the pressure P in the piping is shown together with the variation AP1 in the last minute The waiting time is set in the test configuration menu The stabilization can be interrupted any time by EP essing the i key an UNI 11137 STANDARD UNI 11137 STANDARD 9 WARNING WARNING End the tightness End the tightness test test QUIT QUIT 37 4 9 Flow Chart Configure Analysis Menu Do not insert the gas probe in the chimney Or automatically after 10 seconds 01 Natural gas Jerry Smith full manual Autozero Bat 94 2 Time 11 33 Date 09 18 Autozero cycle end Insert the gas probe in the chimney to initiate analysis Or automatically after 10 seconds Op Adju
13. and can be set by the user from 15 to 99 minutes Please note that UNI 7129 standard requires a stabilization time of at least 15 minutes anyway there is the possibility to skip stabilization by pressing button Once the stabilization parameter has been set the user can proceed with the tightness test Selecting the item Start Test the test pressure required by the standard is shown and then a screen with actual pressure applied to the instrument inputs is displayed After having zeroed the instrument and subsequently having charged the piping with at least 100 mbar the tightness test can be started through the option TEST which actually starts the stabilization phase In the stabilization screen the following values are displayed P Actual pressure measured by the instrument in the selected measurement unit API Pressure variation in the last minute updated every 10 seconds This value gives a rough indication about the stabilization level reached in the piping system Wait time Remaining time before the stabilization phase ends 29 Once the stabilization phase is terminated the tightness test is started This test is performed by observing how the pressure decays in time during a fixed 15 minutes interval as stated in the applied standard During the tightness test phase the following values are displayed E Pi Pressure measured at the beginning of the test P2 Pressure actually measured by the instrument A
14. are displayed P Actual pressure measured by the instrument in the selected measurement unit API Pressure variation in the last minute updated every 10 seconds This value gives a rough indication about the stabilization level reached in the piping system Wait time Remaining time before the stabilization phase ends Once the stabilization phase is terminated the tightness test is started This test is performed by observing how the pressure decays in time during a fixed 1 minute interval as stated in the applied standard During the tightness test phase the following values are displayed Pi Pressure measured at the beginning of the test P2 Pressure actually measured by the instrument AP Pressure variation with respect to the initial value In case the actual pressure is lower than the initial value pressure is decreasing this value has a negative sign Qtest Is the calculated leakage measured in dm h according to the conditions under which the test has been performed i e the gas used for the test as well as the final pressure measured during the test Qref is the calculated leakage measured in dm h according to the reference conditions described in the standard it is related to the gas to be used in the piping as vvell as to the reference pressure Result is the result of the tightness test Compliant piping suitable for operation when the leakage flow calculated in the reference conditions is lower than 1 dm h The sy
15. as explained in point 9 of section 5 8 It is important not to leave the power supply connected for more than 12 hours in order not to damage the internal backup battery responsible of correct working of the clock and the NO sensor biasing 3 2 1 Battery check and replacement The status of the internal battery can be checked during instrument auto calibration or even after if necessary by pressing the information key and accessing the battery capacity submenu The menu displays the battery s residual capacity and voltage If battery charge appears to be low let it discharge completely and then carry out a full 100 charge cycle by connecting the instrument to the power pack for 2 hours If the problem persists replace the battery pack with an E INSTRUMENTS original or contact the SERVICE CENTER to carry out the necessary repairs 3 22 Use with external power pack The instrument can work with the batteries fully discharged by connecting the external power pack provided Kindly note that while the battery is charging some heat is generated which increases the instrument s internal temperature This may lower the accuracy of some readings The air temperature must be measured using the air temperature probe since the internal sensor might lie at a different temperature with respect to ambient CAUTION Before connecting the power pack to the mains check that the voltage data shown on the data plate corresponds with that provided If the
16. c The sensor was not allowed the necessary adjustment time or the instrument was left with a low battery for too long A pressure sensor error is shown in the pressure draft screen There is a calibration problem Send the instrument to a service center The analysis screen gives a flue gas temperature Tg error a The thermocouple is not connected connect the thermocouple to the analyzer b The sensor has been exposed to temperatures greater or lower than its operating temperature range c The thermocouple is faulty Send the complete probe to a service center The following symbol appears on the analysis screen The instrument is not able to calculate a numerical value based on the flue gas analysis conducted The are replaced by numbers when the analyzer detects valid combustion data Max Lim or Min Lim appears on the analysis screen The relative sensor is detecting a value that is beyond the analyzer s measuring range Max Lim or Min Lim are replaced by numbers when the instrument reveals values that are within the measuring range 52 The sample pump sounds as though it is running slowly tends to stop or does not even start a Sample flow is obstructed Check that the water filter is clean and that it is not completely soaked Also check that the hose connected to the probe is not crushed b Sample intake flow is obstructed Chec
17. contrast Butane Automatic analysis oon v Natural gas Natural gas Methane Natural gas 2 0il Natural gas L P G Diesel oil Fuel oil gt Methane G20 y CONFIGURATION MEASUREMENT UNITS MEASUREMENT UNITS MEASUREMENT UNITS Fuel CO CO hMeasurement units NO NOx NO NOx O2 Reference Pressure Pressure Pressure Display contrast Temperature Temperature Temperature Automatic analysis v MEASUREMENT UNITS MEASUREMENT UNITS MEASUREMENT UNITS 4 co co NO NOx NO NOx Pressure Pressure Pressure Temperature Temperature Temperature MEASUREMENT UNITS CO NO NOx gt Pressure Temperature MEASUREMENT UNITS CO NO NOx Pressure gt Temperature MEASUREMENT UNITS co NO NOx Pressure Temperature Ll MEASUREMENT UNITS co NO NOx Pressure Temperature MEASUREMENT UNITS 4 co NO NOx Pressure Temperature 3 MEASUREMENT UNITS co NO NOx Pressure Temperature BE CONFIGURATION O2 REFERENCE Fuel Measurement units gt 02 Reference Display contrast Automatic analysis v O2 REFERENCE O2 REFERENCE co oo 7 NO NOx 7 O2 REFERENCE CONFIGURATION CONTRAST Fuel Measurement units 02 Reference gt Display contrast Automatic analysis v O2 REFERENCE co NO NOx O2 REFERENCE CONFIGURATION AUTOMATIC ANALYSIS Fuel Measurement units 02 Reference Display contrast gt Automatic a
18. end of the combustion analysis carefully remove the sample probe and remote air temperature probe if used from their relative ducts taking care not to get burnt Let the instrument draw in fresh air for at least a few minutes or at least until the values displayed return to their original values that is 20 9 21 0 for O and 0 for CO NO NO Switch off the instrument by pressing the On Off key At this point if the instrument has detected a concentration of CO and or NO greater than 100 ppm a self cleaning cycle will be initiated during which the pump will draw fresh outside air until the gas levels drop below the defined values At the end of the cycle lasting no longer than 3 min the instrument will switch itself off automatically 4 12 Measuring the Differential Pressure OPTIONAL KIT The instrument is fitted with an internal temperature compensated piezoresistive transducer to measure positive and negative pressures This sensor which is mounted on the instrument is of the differential type If the special KIT is purchased the sensor can be used to measure the differential pressure thanks to the positive and negative pressure connectors The measuring range varies between 1000 00 mm H O and 1000 00 mm H 0 4 13 Resetting the Microprocessor In order to access the reset pushbutton proceed as follows Apply a slight outward pressure on the cover of the printer slide it out and remove it appear as shown below
19. measure temperatures as high as 999 92C A Pt 100 resistance thermometer located inside the instrument measures the internal temperature this sensor is also used to measure the ambient temperature Should the user want to measure the combustion air temperature directly in the intake duct the optional remote Pt 100 sensor must be used this measurement is recommended for more precise calculation of plant efficiency Remote temperature probe The temperature probe consists of a Pt 100 probe complete with 2 m cable and 7 5 17 mm pit adapter pos in Fig 2 2 This probe is used to measure the combustion air temperature within a range of 10 C to 100 C when boiler efficiency is to be calculated precisely Pressure sensor The instrument features an internal piezoresistive sensor to measure the stack draft negative pressure and other parameters if required gas network pressure pressure drop across filters etc The user can switch from flue gas analysis to this reading by simply pressing a key Sample and pressure inputs Pos in Fig 2 2 is the input of the sample probe complete with water separator and particulate filter Pos and N in Fig 2 2 are respectively the pagitive and negative internal differential pressure sensor inputs The negative input P is used to measure the stack draft to perform the pipes tightness test and generally all the pressure tests It must be connected to the hose from the sampling probe withou
20. syringe PIPING VOLUME ADD TUBE Vtot 0 0 dm Select material with keys Volume measure ial dl amon gi tas P Subtract tuba S teel Copper PE Zero volume ADD TUBE Vtub Select the nominal Material diameter with the gt Diameter Length w Akey S Select the figure to be modified with the i eys Modify the value of the n Am ADD TUBE PIPING VOLUME SUBTRACI TUBE vtot 1 2 am Select material with keys Volume measure aterial n amongi tas paubtract tube a Steel Copper PE Zero volume SUBTRACT TUBE Vtub Select the nominal Material diameter with the gt Diameter Length w akey S Select the figure to be modified with the eys Modify the value of the YA SUBTRACI TUBE PIPING VOLUME ZERO VOLUME Vtot 25 0 dm WARNING Zero piping volume WARNING Volume measure Zero piping volume Add tube Subtract tube ZERO VOLUME gt Zero volume QUIT QUIT a UNI 11137 STANDARD Start test Stabilization Piping volume gt Combustible gas Test gas COMBUSTIBLE GAS pCity gas Natural gas L P G COMBUSTIBLE GAS City gas COMBUSTIBLE GAS City gas Natural gas pL P G UNI 11137 STANDARD Start test Stabilization Piping volume Combustible gas gt Test gas AI TEST GAS gt City gas Natural gas L P G Air TEST GAS TEST GAS City gas Natural gas TEST GAS City gas Natural gas L
21. the functions label The roll of paper is positioned at the upper end on the rear and may be easily replaced by removing the snap on flap The pneumatic connectors for flue gas sampling and pressure draft measurement are installed on the lower end of the instrument Connectors are provided on the right hand side of the analyzer for connecting the thermocouple sample probe and Pt 100 air temperature probe On the left hand side there is a socket outlet for connecting the external power supply and an 8 pin min DIN for serial interface or Deprimometer optional The HMI consists of a constantly active backlit graphic LCD display and membrane keypad Menu screens and all user messages are in English or in the language specified in the purchase order Use of the analyzer is simplified by symbol keys that give direct access to main instrument functions Shifting between the various menu screens is easy and user friendly thanks to four cursor keys an key and key 1 2 Configurations and Sensors The combustion analyzer features a large backlit alphanumeric display and built in impact printer for ordinary paper rechargeable battery pack and user replaceable pre calibrated sensors THE 1100 2200 SERIES is available in three versions 1100 Dual sensor combustion analyzer O2 CO with memory The 1100 is used to conduct direct O and CO analyses and make additional measurements and calculations of COs air flue gas and differential temperatures
22. three tests are over if Manual Printing has been chosen the instrument will display the average of the three tests with the possibility of recalling the individual values If desired the user can then print the relative data total complete etc On the contrary if Automatic Printing was selected the instrument will print the test data automatically based on the current print settings without displaying the average test values Caution when in automatic mode draft smoke and ambient CO NO measurements must be taken before initiating the flue gas analysis If on the other hand manual analysis mode is chosen flue gas analysis will proceed manually please see relative Flow Chart In this case the print settings and automatic test duration will not be considered At this point manual analysis may commence first waiting at least two minutes until the displayed values stabilise The user can 43 then proceed with data storage if required or print the analysis report directly The latter vvill be printed in the format set beforehand When all three tests are over the user can recall the average analysis screen containing all the data necessary for compiling the maintenance log of the boiler or plant In both automatic and manual modes all the pollutant values CO NO NO can be translated into normalised values referenced to the previously defined O level by simply pressing the button 4 11 4 End of Analysis At the
23. 0 2 vol co 20 ppm 0 400 ppm H compensated Electrochemical 0 8000 ppm 1 ppm 5 measured value 400 2000 ppm NOx Filtration 10 measured value 2000 8000 ppm 5 ppm 0 100 ppm NO Electrochemical 0 4000 ppm 1 ppm 5 measured value 00 1000 ppm 10 measured value 000 4000 ppm NOx Calculated 0 5000 ppm 1 ppm co Calculated 0 99 9 vol 0 1 vol Air temperature PT100 RTD 10 0 100 0 C 0 1 C 1 C o A 2 C 10 200 C Flue gas temperature type K thermocouple 10 0 999 9 C 0 1 C 1 measured value over 200 C Differential temp Calculated 100 0 1000 0 C 0 1 C 1 5 meas val 40 045 hPa 105 00 1 00 hPa 5 measured value 1 00 0 40 Draft Pressure Semiconductor 105 hPa 0 01 hPa de hPa 0 40 0 40 hPa 5 measured value 0 40 1 00 hPa 0 5 meas val 0 045 hPa 1 00 105 00 hPa Excess air Calculated 1 00 23 00 0 01 Stack loss Calculated 0 0 100 0 Yo 0 1 Yo Efficiency Calculated 0 0 100 0 0 1 Yo Smoke index External instrument 0 9 1 Data relative to concentration accuracy are referred to an instrument operating at a constant temperature within the correct operating range 5 C to 40 C that has been on for at least 15 minutes is powered by the internal battery and has completed auto calibration Data relative to pressure and draft measurement accuracy are referred to an instrument o
24. 28 28 29 32 38 39 43 43 43 43 44 44 44 TABLE OF CONTENTS 5 0 6 0 7 0 MAINTENANCE 5 1 Routine maintenance 5 2 Preventive maintenance 5 3 Cleaning the sample probe 5 4 Maintaining the water trap filter unit 5 5 Replacing the particulate filter 5 6 Life of O CO and NO sensors 5 7 Gas sensor life 5 8 Replacing the O CO and NO sensors 5 9 Replacing the battery pack 5 10 Replacing the printer paper roll TROUBLESHOOTING 6 1 Troubleshooting guide SPARE PARTS AND TECHNICAL ASSISTANCE 7 1 Spare parts P2 Accessories 1 3 Service Centers 46 46 46 46 46 47 47 47 47 50 51 52 52 54 54 54 54 1 0 INTRODUCTION 1 1 General Overview of the Combustion Gas Analyzer The 1100 2200 Series are portable combustion analyzers that were meticulously designed to meet the statutory requirements and specific customer demands They may be provided in a rugged ABS carry case or waterproof shoulder bag The instrument contains two cards with all the basic circuitry pre calibrated measuring cells sample pump membrane keypad backlit graphic LCD display high capacity rechargeable Ni MH battery pack and impact printer The two halves of the case are firmly secured by eight screws on the rear of the instrument The pneumatic circuit and measuring cells inclusive of micro module are located on the back side of the plastic case and are easily accessed for maintenance and replacement by removing the cover carrying
25. Decide which sensor is to be replaced 3 Remove the relative electrical connection Fig 4 4 The sensor is a bayonet type turn it counter clockwise to remove Fig 5 When rotating the sensor make sure you do not exert pressure on the printed circuit board above only exert force on the plastic capsule After turning the sensor pull it upwards Fig 6 5 Insert the new sensor making sure that the electrical connection faces outwards and not towards the inside of the instrument 6 Turn the sensor clockwise until it snaps in When rotating the sensor make sure you do not exert any pressure on the printed circuit board above but only on the plastic capsule 47 7 Reinstate the electrical connection Fig 3 8 If the S2 sensor is replaced CO Carbon Monoxide remove the polarising block from the printed circuit board above the sensor Fig 3 with the aid of pliers When extracting the block hold the printed circuit board steady so as not to subject the connections between the printed circuit board and the sensor capsule below to mechanical stress 9 Replace the rear flap on the sensor compartment and retighten the two screws Fig 1 Correct sensor operation may be verified by switching on the instrument and accessing the Sensor Diagnostics menu It is normal for newly installed sensors to give a current error you must wait until the sensor polarisation adjusts The following chart lists the minimum adjustment time necessary fo
26. Display average Select memory AA BAA RA Recall the average test values Recall memory Delete single v gt Print report Print setup Paper feed Print test PRINT SETUP Print report gt Copies gt Print setup Model Paper feed If desired set the preferred number of copies and analysis report format Print test gt Print report Print setup Paper feed a Print the analy sis rep ort Print test 41 a iy SA als DES EG de SA DAAD ele ad Er Hov to proceed in automatic mode An 1 25 TE 190 2c O2 421 If when configuring test parameters manual printing has been selected see example the average values will be ares disp layed after the third test values have been read These may be printed by activating the relative menu If on the TE 190 1C other hand automatic printing has been selected the average test values will be printed automatically gt Print report Print setup Paper feed Print test Print report gt Print setup Paper feed If desired set the preferred number of copies and analysis report format PRINT REPORT 42 gt Print report Print setup Paper feed Print test Memory 01 Analysis average Model total Print the analysis report 4 11 FLUE GAS ANALYSIS To perform complete flue gas analysis follow the instructions below 4 11 1 Switching on the instrument and auto calibration Press the On Off key to switch on the instrument an introd
27. Doe Select the test operator PRINT SETUP Setup the report printing selecting the number of copies and the type of report to print AUTOMATIC ANALYSIS Mode Select the Measure mode automatic or manual If automatic mode Duration Print is selected define the test time and print mode automatic or manual 27 4 7 Draft Menu The DRAFT menu gives access to the flue chimney draft measurement As we are dealing with a depressure the sign of the draft is opposite with respect to that of pressure and the correct values for a natural draft boiler must be positive by definition During draft measurement please use P input which is normally used for pressure measurement the instrument itself will provide in return the measurement value with the correct sign according to standard UNI10845 Before performing the measurement the instrument allows the user to input the external air temperature as required by the standard Afterwards the measurement screen is reached here the user can acquire the value displayed in order to add it to the running analysis measurements or alternatively print the relevant ticket through the PRINT menu NOTE The measurement may not be accurate due to condensation inside the fumes probe Should you notice an inaccurate or unstable reading on the instrument it is advisable to disconnect the fumes probe from the instrument itself and purge pipes by blowing with a compressor In order to
28. N STABILIZATION STABILIZATION Start test gt Wait time Vait time EE min gt Stabilization NORMA UNI 7129 NORMA UNI 7129 NORMA UNI 7129 NORMA UNI 7129 gt Start test Stabilization WARNIN Charge the pipe to 0 O GnPa the test pressure 100 00 hPa O OOnpa Pressurize the piping and select TEST with the key 100 00nra T NORMA UNI 7129 EE IG During stabilization the pipe pressure P is displayed and El 1060200525 also its variation APT during the last minute The ma 099813 stabilization wait time is the one set in the test Onis mi configuration menu Stabilization can be stopped at any time by pressing on UNI 7129 STANDARD UNI 7129 STANDARD Pl 100 00hPa WARNING WARNING P2 99 99hPa End the tightness End the tightness AP 0 01hPa test test Result 15 00 UNI 7129 STANDARD sad Automatically after 15 minutes UNI 7129 STANDARD P1 100 00hPa P2 99 99hPa AP 0 01hPa Result tight gt Print report Print setup Paper feed Print test TIGHTNESS TEST New piping bExisting piping UNI 11137 STANDARD gt Volume up to 25 dm Volume calculated W UNI 11137 STANDARD Volume up to 25 dm gt Volume calculated gt UNI 11137 STANDARD gt Start test Stabilization Piping volume Combustible gas Test gas Start test gt Stabiliza tion Piping volume Combustible gas Test gas ku UNI 11137 STANDARD Start t
29. NTS highly qualified staff is always at your disposal and will provide you with all the sales technical application and maintenance details required The service center will always return the instrument to you in good condition and in the shortest time possible Calibration is performed using gases and instruments comparable with National and International Specimens Annual servicing is accompanied by a specific calibration certificate that is a guarantee of perfect instrument performance as required by UNI 10389 besides being indispensable for users wishing to maintain ISO 9000 status 5 3 Cleaning the sample probe When you finish using the sample probe clean it thoroughly as described below before returning it to its case e Disconnect the sample probe from the instrument and from the water trap Fig a b then blow a jet of clean air into the hose of the probe refer to Fig c to remove any residual condensate that may have formed within Fig a Maintaining the water trap filter unit To remove the water trap just unscrew the two ends as shown I pes in the adjacent figure Clean all the filter parts using water only dry the components and reassemble the filter 4 Fig c 46 5 5 Replacing the particulate filter If the particulate filter has any cracks or appears black especially on the inner surface see adjacent example it has to be replaced S immediately In this way gas flow is not obstructed
30. P Pressure variation with respect to the initial value In case the actual pressure is lower than the initial value pressure is decreasing this value has a negative sign Result Reports the test result tight when the pressure drop is greater than 10 Pa leak when the pressure drop is less than 10 Pa Positive pressure changes are symptom of a temperature change meanwhile the test is performed Should this happen it is advisable to repeat the entire test Existing piping UNI 11137 STANDARD The standard UNI 11137 can be adopted for testing already existing internal piping systems This test requires to charge the piping up to the test pressure then wait for an unspecified stabilization time until the thermal effects caused by the test gas compression are nullified and then calculate the amount of the possible leakage from the measure of the pressure decays in 1 minute time The test pressure should be as close as possible as the reference conditions following explained REFERENCE CONDITIONS According to the combustible gas to be used in the piping the tightness test must be performed in one of the following reference conditions City gas Reference pressure for test with supply gas 1000 Pa Test pressure with air 5000 Pa Natural gas Reference pressure for test with supply gas 2200 Pa Test pressure with air 5000 Pa L P G Reference pressure for test with supply gas Standard to be defined Somebody proposes 5000 Pa Test pressure with air S
31. ate 09 1 Autozero cycle end Insert the gas probe gt 1 Jerry Smith in the chimney to 2 John Doe initiate analysis 3 Jane Doe Select the test operator Setup the printing options Or automatically after 10 seconds Duration Print Select analysis mode 39 Record the draft value 174 8C NOx How to proceed in manual mode quick sequence MEMORY SAVE ANALYSIS Save analysis Display average Select memory Memorise test 1 Recall memory Delete single v MEMORY SAVE ANALYSIS gt Save analysis Display average Select memory Memorise test 2 Recall memory Delete single v MEMORY SAVE ANALYSIS gt Save analysis Display average Select memory Memorise test 3 Recall memory Delete single v MEMORY 02 4 27 Save analysis CO2 gt Display average 9 37 Select memory An 1 25 Recall memory Tf 190 1C Delete single v Recall the average test values gt Re fO2 Mem 01 A Mk gt Print report Print setup Paper feed Print test Print report gt Print setup Paper feed If desired set the preferred number of copies and analysis report format PRINT REPORT gt Print report Print setup Paper feed Print the analysis report Print test How to proceed in manual mode quick sequence SAVE ANALYSIS Memorise test 1 SAVE ANALYSIS M emorise test 2 SAVE ANALYSIS M emorise test 3 An 1 26 TE 190 0C MEMORY Save analysis F P
32. be sure there is no humidity it is suggested to perform the measurement by means of the transparent rubber pipe supplied on issue 4 7 1 Flow Chart Draft Menu d Activates the Draft Menu Connect the probe pressure input hose to T outdoor 20 C T outdoor Bac T outdoor Bc the instrument P input J Enter the external air temperature WARNING WARNING WARNING Use P negative Use P negative Use P negative inlet inlet inlet Before starting the pressure zeroing sequence pay attention to remove the gas probe from the stack Pressure zeroing is accomplished by pressing o with the ZERO option highlighted in the background y Insert the probe in the chimney and measure the draft In order to add the draft value to those of the ongoing analysis please select KEEP through the right arrow EER key then press OK For intout of the ticket with the draft value enable 0 05hPa Paper teens the PRINT menu through the reievant key then proceed as in the combustion En ees analysis printing A draft value acguired into memory can be deleted by pressing again the draft key a series of dashes will appear in place of the measurement value after this select the KEEP option with OR o Once the data is stored the instrument progresses automatically from the Draft Menu to the Analysis Menu 28 NOTE The draft values to be stored in the memory must be acquired before storing the analysis data 4 8 Readings Menu Th
33. de in RAUCLAIR supplied to measure a pressure value within the range stated in the technical features connect the pipe to P input During the pressure measurement the HOLD function is made available which allows to freeze the value shown on the display by pressing HOLD key Tightness test The 1100 2200 analyzers can perform the tightness test on heating plants which use combustible gases according to the standards UNI 7129 and UNI 11137 respectively applicable to new or renewed piping and to existing piping The result of this tightness test whose steps are described in the following can be printed once acquired by starting the print menu in any of the screens of the Tightness Test menu Nev piping UNI 7129 STANDARD The standard UNI 7129 can be adopted for testing new piping systems or reconditioned ones This test requires to charge the piping up to a pressure of at least 100 mbar then wait for a stabilization time of at least 15 minutes required for nullifying the thermal effects caused by the test gas compression and finally check for the tightness of the piping by analysing the way the pressure eventually decays against time This check expects for no difference between two pressure readings performed in 15 minutes and with a manometer having a minimum resolution of 10 Pa The 1100 2200 analyzers allow the user to customize the stabilization phase through the following parameter WAIT TIME it is the stabilization time
34. e picture Re insert the paper plastic door and fit the edge of the paper roll into the slot pointed by the arrow Advance some paper in the printer through the Print Menu Paper Feed Completely close the printer plastic door paying attention to insert the paper roll into the relevant slot located on the plastic door 51 6 0 TROUBLESHOOTING 6 1 Troubleshooting guide PROBLEM PROBABLE CAUSES AND REMEDIES The instrument does not work at all When the On Off pushbutton is pressed the instrument does not come on a Keep the On Off key depressed for at least 2 seconds b The battery is low connect the battery charger to the instrument c The battery pack is not connected to the instrument remove the cover from the battery compartment and connect the connector of the battery pack to the outlet on the printed circuit board d The instrument is faulty send it to a service center The battery symbol is empty on the inside The batteries are low The instrument will remain on for a couple of minutes after which it will switch off connect the battery charger After auto calibration is complete the sensor diagnostics screen appears and gives an error for one or more cells a Auto calibration took place while the flue gas was being sampled b The O sensor is faulty is not connected correctly or is not connected at all Check the above points also referring to sections 5 6 5 7 and 5 8
35. e the faucet again 30 e Wait for the pressure in the piping to stabilize After a few seconds the instrument returns to the volume input screen in which the measured volume is shown The proposed value can be accepted by pressing the button modified through the arrow keys or rejected through the Esc key COMBUSTIBLE GAS consider that the amount of the leakage is strictly related to the nature of the gas under pressure When the tightness of a piping has to be evaluated it is mandatory to specify the family to which the gas belongs City Gas Natural Gas or L P G TEST GAS again the amount of the leakage is related to the nature of the gas under pressure therefore it is mandatory to specify the type of the gas used City Gas Natural Gas L P G or air Please note that the gas used for the test could also be different from the gas to be used in the plant and could even be a not flammable gas Once the stabilization parameter has been set the user can proceed with the tightness test Selecting the item Start Test the test pressure required by the standard is shown and then a screen with actual pressure applied to the instrument inputs is displayed After having zeroed the instrument and subsequently having charged the piping to a pressure close to the reference values indicated tightness test can be started through the option TEST which actually starts the stabilization phase In the stabilization screen the following values
36. ed to extremely high or extremely low temperatures the quality of the display may be temporarily impaired Display appearance may be improved by acting on the contrast key Printer Internal 24 column impact printer for use with ordinary paper pos in Fig 2 2 Thanks to the use of ordinary paper and an ink ribbon running costs are lower and the printout is more legible and longer lasting when compared to printouts obtained by other systems besides being much more resistant to heat The print menu is accessed by pressing the relative key and besides enabling read out printing the menu also allows you to modify print settings and to advance the paper manually so as to facilitate paper roll replacement Battery charger The instrument is provided with a 12VDC 2A power supply pack to charge the internal batteries The socket for connecting the battery charger to the instrument is shown as tem in Fig 2 2 When the battery starts charging a red LED lights up alongside socket outlet in Fig 2 2 Serial cable Item in Fig 2 2 represents the serial communications interface for hooking up the instrument to a personal computer or for connecting Deprimometer optional probe Sample pump The sample pump located inside the instrument is a DC motor driven diaphragm pump powered by the instrument and is such as to obtain optimal flow of the sampled gas being analysed Remote sampling unit Stainless steel probe with plastic handgrip pos Qi Fig
37. es of printing the analysis under acquisition printing a single analysis after recall from memory and printing an average analysis after recall from memory Go ahead for printing is given by pressing re J with the PRINT option highlighted in the background PAPER FEED report setup Paper feed feed test PAPER FEED Paper feed PRINT TEST report setup Report test print feed test Good bye PRINT TEST t Report test print Please wait 24 4 6 Analysis Menu Through this Rey the analysis results are displayed Moreover the operator is allowed once this key is further depressed to display and possibly modify the analysis parameters before proceeding with the measurements Measured values are Os CO NO Tg Ta Oxygen content Yo in flue gases Carbon monoxide concentration in flue gases Nitrogen monoxide concentration in flue gases for 2200 analyzers only Flue gas temperature Combustion supply air temperature Ambient Air or Incoming Supply most useful for condensing boilers need External Air Probe for this measurement part AACSA0O1 Calculated values are Kair CO AT NOx Qs Eff 4 6 1 Excess air i e ratio between the effectively supplied combustion air volume amp the ideal stoichiometric theoretical value Carbon Dioxide content in flue gases Difference between flue gases temperature and combustion supply air temperature Ni
38. est Stabilization gt Piping volume Combustible gas Test gas UNI 11137 STANDARD Selected test is valid for volume pipes up to 25 dm 25 liters It is not reguired to know and enter the UNI 11137 STANDARD volume of the pipe since it is assumed to be 25 dm bstart test In this way the leakage rate is actually rounded up Stabilization Combustible gas gt and better guarantee the validity of a compliant meek gas result The test procedure is not described in details because it is the same as the calculated volume shown in the flow chart except for the volume size STABILIZATION STABILIZATION gt Wait time 15 min Wait time Hin PIPING VOLUME PIPING VOLUME gt Vtot 0 0 dm Volume measure Add tube Volume measure Subtract tube Add tube Zero volume Subtract tube PIPING VOLUME VOLUME MEASURE Vtot 0 0 dm Take one syringe gt Volume measure 100 ml of gas Add tube From the piping Subtract tube then press OK Zero volume v o VOLUME MEASURE Inject the syringe contents in the piping VOLUME MEASURE R 4 Pressure not stable Please wait STABILIZATION Wait time Bin Select the figure to be modified with the d poys Modify the l f th value o YA When the volume measurement procedure is correctly terminated the analyzer automatically shows the measured value otherwise it reguires to repeat the gas injection with the
39. ic Vbat 6 43 V Info Service INFORMATION FUEL PARAMETERS Battery status bNatural gas gt Fuel parameters L P G Sensors diagnostic Diesel oil Info Service Fuel oil Methane G20 v FUEL PARAMETERS Natural gas FUEL PARAMETERS t Natural gas FUEL PARAMETERS Natural gas FUEL PARAMETERS Natural gas L P G Diesel oil Fuel oil pMethane G20 v FUEL PARAMETERS A Natural gas FUEL PARAMETERS 12 To return press Q FUEL PARAMETERS Al 0 6600 B 0 0100 CO2t 11 70 LHV 51000 kJ kg HHV 56500 kJ kg FUEL PARAMETERS Al 0 6300 B 0 0080 CO2t 13 90 LHV 45930 kJ kg HHV 49800 kJ kg FUEL PARAMETERS 0 6800 0 0070 15 10 42900 kJ kg 45700 kJ kg FUEL PARAMETERS Al 0 6800 By 0 0070 CO2t 15 70 LHV 41100 kJ kg HHV 43500 kJ kg FUEL PARAMETERS Al 0 6741 B 0 0088 CO2t 11 70 LHV 50050 kJ kg HHV 55550 kJ kg FUEL PARAMETERS Al 0 6729 B 0 0070 CO2t 13 70 LHV 46350 kJ kg HHV 50390 kJ kg FUEL PARAMETERS 0 6861 0 0068 14 007 45800 kJ kg 49620 kJ kg the previous screen INFORMATION t Battery status Fuel parameters sensors diagnostic Info Service INFORMATION t Battery status Fuel parameters Sensors diagnostic gt Info Service O SENSOR DIAGNOSTIC 4 po sensor Type 5F0 CO sensor Serial 02687859 NO sensor Is 404 uA SENSOR DIAGNOSTIC Calibr SENSOR DIAGNOSTIC O SENSOR DIAGNOSTIC 4 t 02 sensor Type ASF
40. instrument is damaged as a result of it being connected to a voltage other than that specified the warranty shall cease to be valid 3 3 Connecting the sample probe The sample probe consists of a stainless steel pipe with plastic handgrip and internal Type K thermocouple Ni NiCr for measuring flue gas temperatures as high as 800 C 14702F The probe is connected to the analyzer through two flexible hoses a filter unit and a compensated cable for the thermocouple Connect the polarised connector of the thermocouple to the relative socket on the right hand side of the instrument The connector cannot be inserted wrongly thanks to different attachment widths Slip the shorter hose into the filter unit particulate water trap and connect the filter unit to the main connector on the instrument marked A The longer of the two hoses terminated with a male connector must be connected to the negative pressure input of the instrument which is marked with letter P The connectors have different diameters to prevent erroneous connection preventing the user from damaging the instrument 4 0 OPERATION 4 1 Keypad overview On Off Select Modify Cancel Exit Confirm Print Menu Memory Menu Zoom on Analysis Configure Menu Draft Menu Readings Menu Analysis Menu Info Menu
41. is menu is used to access the following readings Smoke One to three smoke values can be input through an optional external device smoke pump The instrument then automatically calculates the average value of the input data These measurements can be either stored in memory together with the combustion analysis data or printed on a ticket Ambient CO NO This type of analysis lets the user measure the CO and NO values present in the environment with the scope of checking the personal safety conditions of a specific working environment The instrument leaves our factory with the following preset threshold values CO 35 ppm Recommended exposure limit REL stipulated by the National Institute for Occupational Safety and Health NIOSH equivalent to 40 mg m and calculated as an 8 hour Time Weighted Average TWA NO 25 ppm Recommended exposure limit REL stipulated by the National Institute for Occupational Safety and Health NIOSH equivalent to 30 mg m and calculated as an 8 hour Time Weighted Average TWA If during these readings the measured values exceed the established threshold values the user will be warned by an audible alarm and the displayed values will start flashing In this condition the keypad will block automatically until the alarm is acknowledged the keys are pressed or until the measured values drop below the allovvable limits Pressure It is possible through the use of the external flexible pipe ma
42. k Printer autonomy Up to 40 analysis reports with batteries fully charged Internal data storage 600 positions with storage of three analyses each including date time and client s name User details 3 programmable user names Printout heading 4 lines customizable by the user Display Backlit graphic LCD display measuring 42 x 60 mm Communications port Two way RS232 serial port Filter With replaceable cartridge Smoke Using an external hand operated manual pump capable of entering data and printing the results on the analysis report Operating temperature range 5 C to 40 C Storage temperature range 10 C to 50 C Operating humidity range 20 to 80 RH Air pressure Atmospheric Outer dimensions Analyzer 30 7 x 10 5 x 9 6 cm W x H x D Case 48 2 x 37 5 x 16 cm W x Hx D Weight Analyzer 1 l kg Total 4 5 kg 2 2 Overview of Combustion analyzer Components Case Rigid plastic case with outer dimensions 48 2 x 37 5 x 16 cm Seven internal dividers allow the instrument and relative accessories to be safely lodged Fig 2 2 Keypad Adhesive polyester keypad with preformed keys featuring main control functions pos Q in Fig 2 2 Display Backlit 128 x 64 pixel LCD display pos Q in Fig 2 2 with 8 lines x 20 characters available Allows the user to view the measured parameters in the most comfortable format a Zoom function displays the measured values in magnified form CAUTION If the instrument is expos
43. k that the particulate filter is clean c The pump is not connected as it should be Remove the rear flap and check that the pump s electrical connector is connected to the printed circuit board d Pump is faulty Replace the pump unit e Pump is disabled The key combination has been pressed To re enable the pump switch off the instrument and then switch it on again The rear lighting of the display is not on The backlighting LED s are faulty Contact the nearest service center to replace the display The batteries last less than 8 hours a Battery capacity is limited by low temperatures To achieve a longer battery life it is recommended to store the instrument at higher temperatures b The battery pack is old Battery capacity tends to diminish with age If battery life has become unacceptable replace the battery pack The values shown in the analysis screen are not reliable a Sensor s is are faulty Check that the sensors are installed correctly by accessing the sensor diagnostics menu b The sample probe connection presents a leak Check all joints and the conditions of the hose c Pump is faulty Replace the pump unit d The instrument is faulty Send it to a service center for repair During the tightness test a sensor error is reported Check for the correct connection of the hose to the positive pressure input 53 7 0 SPARE PARTS AND TECHNICAL 7 1 Spare parts
44. lt gt 7 s e O YZ _ A BCDEFGHI Yz I a bedefghi 19 4 4 Memory Menu This menu is used to display and print individual and average values of the analysis data stored in memory Analysis data can be ordered either by memory position or by storage date draft and smoke values can also be recalled The Print Menu is enabled in both the analysis screen and draft and smoke level screen within the Recall Memory menu Save analysis This submenu displays the current active MEMORY and the data stored within and allows the user to record new values or to overwrite them if these are already present and complete Display average Displays the average of the analysis data stored in the active memory Select memory Allows the user to select the memory within which to record any effected analyses or other data such as draft smoke and ambient CO NO values When the menu is accessed a preview of all saved data will appear Recall memory This menu just like the previous one lets the memory be selected on the basis of the stored position or storage date thereby letting all stored data be displayed individual and average readings draft smoke and ambient CO NO values Delete single Allows the user to erase the data stored for a single memory A confirmation is required in order to avoid an accidental loss of the formerly stored data Delete all This is used to cancel the entire contents of the 600 memory positio
45. n in this case the volume value is not required because through an overestimation the piping is assumed as having a volume of 25 dm The second path requires to input the piping value either directly through the keyboard when known or by a calculation which takes into account the sum of the contributions due to each single pipe section or finally by measuring it through a simple procedure which requires the injection into the piping of a known gas quantity through a graduated syringe In case the volume calculation is used for each single piping section the Add tube option must be selected and then input the relevant material nominal diameter and length The 1100 2200 analyzers calculate the single section volume and adds it when confirmed to the total piping value For error correction or for modifying the ongoing calculation the subtraction operation is also available When the Volume measurement option is selected instead the procedure described also in the flow charts of the tightness test according to UNI 11137 is described in the following steps e Close both faucets in the kit assembly supplied for the test execution e Connect the graduated syringe to the hose which in the assembly is opposed to the pump e Open the faucet on the side where the syringe is applied and withdraw exactly 100 ml 100 cc of the gas present in the piping Press the button e Inject the gas present in the syringe back into the piping and then clos
46. nalysis v AUTOMATIC ANALYSIS k Mode gt Duration Print AUTOMATIC ANALYSIS g Mode auto Duration 120 s gt Print manual AUTOMATIC ANALYSIS Mode AUTOMATIC ANALYSIS Mode auto Duration El Print manua Mode Duration 16 AUTOMATIC ANALYSIS AUTOMATIC ANALYSIS Mode Duration Print AUTOMATIC ANALYSIS Mode Duration Print AUTOMATIC ANALYSIS Mode Duration Print CONFIGURATION CONDENSATION A Measurement units O2 Reference Display contrast Automatic analysis gt Condensation v CONDENSATION Altitude gt R H air CONDENSATION CONDENSATION Altitude Altitude yn R H air R H air 50 8 CONDENSATION CONDENSATION Altitude Om Altitude 0 R H air sg R H air Ed CONFIGURATION TIME DATE A O2 Reference ime 16 44 Display contrast gt 22 12 03 Automatic analysis EU Condensation gt Time Date v TIME DATE 16 44 22 12 03 EU TIME DATE 16 44 22 12 03 EU TIME DATE TIME DATE Hd 44 ime 16 22 12 03 22 12 03 EU EU TIME DATE TIME DATE TIME DATE TIME DATE TIME DATE 16 44 ime 04 44 PM 22 12 03 12 22 03 usa CONFIGURATION A Display contrast Automatic analysis Condensation Time Date gt Alarms v Number Measure Select the figure to be modified with the keys n le Modify the value of the highlighted figure with keys gt
47. ns even for this option a confirmation is required in order to avoid an accidental loss of the formerly stored data 20 4 4 1 Flow Chart Memory Menu Activates the Memory Menu This menu is used to display and print the individual and average values of the analysis data stored in memory Analysis data can be ordered either by memory position or by storage date draft smoke and ambient CO NO values can also be recalled Inside the Recall Memory menu the Print Menu is only enabled in the analysis screen or in the draft smoke and ambient CO NO values screen y Save analysis Display average Select memory Recall memory Delete single v SELECT MEMORY There are 600 storage areas each of which is capable of storing three test Save analysis er Tn records besides draft smoke and ambient CO NO values The memory EL EE Date 208 can also be selected from the Configure Analysis menu Recall memory Name Delete single The name of the plant can be entered in the Select Memory menu by hd pressing the right cursor key in the Name field SAVE ANALYSIS bsave analysis Analysis data is saved by pressing o with the MEMORIZE option ees highlighted in the background If draft smoke and ambient CO NO Recall memory Delete single values have been measured these are also memorized v Save analysis ion Once a series of test records has been memorized the user can ask the instrument t
48. nstrument built in printer and any other probes or remote devices that may be connected The instrument runs for approximately 9 hours if the printer is not used Should the battery be too low to effect the necessary measurements the instrument can be hooked up to the mains via the power pack provided allowing operations and analysis to proceed The battery will be recharged while the instrument is being used The battery charge cycle is automatic and is divided into three phases e Quick charge this begins as soon as the power pack is connected and the batteries are quickly recharged to 90 of their capacity The process takes approximately 1 hour during which the red LED adjacent to the power pack connector stays on e Normal charge charging is continuous and raises the battery to 100 capacity This phase takes no longer than an hour and the red LED stays off e Trickle charge A trickle current maintains the battery at its 100 capacity It generally takes 2 hours for the battery to charge completely The red LED turns off when the battery is recharged at 90 so the charging should continue for a further hour after the LED turning off The instrument should not be left too long with the battery discharged since this will affect the functioning of the internal clock and will cancel the biasing of the NO sensor Should this happen it is recommended to carry out a 12 hour battery recharge and to allow the sensor the necessary adjustment time
49. nt emits an intermittent audible alarm besides activating a visible alarm wherein the background of the name of the relative reading will start flashing in the analysis screen When the CO and NO concentration thresholds are crossed besides activating the audible and visible alarms the CO and NO solenoid valves may also be set to intervene and thereby interrupt sample flow If the instrument is not fitted with a solenoid valve the sample pump will in any case be stopped Auto calibration Pump This submenu is used to set the duration of the analyzer auto calibration cycle It may also be used to switch off or switch on the sample pump temporarily The sample pump cannot be switched off if the auto calibration cycle is under way Test operator The name of the operator conducting the analysis may be set or modified through this submenu A maximum of three names may be stored The name of the selected operator will be printed on the analysis report Printout heading This allows the Company or Owner s name to be entered in four lines with 24 characters each together with other details e g address tel no This data will be printed on the heading of the analysis report 14 4 3 1 Flow Chart Configure Menu Activates the Configure Menu All selected data can be modified by pressing cursor keys yA To cancel changes and return to the previous menu press a CONFIGURATION gt Fuel Measurement units 02 Reference Display
50. o DDispl R A H a Select menory display the average value The relative analysis report can then be printed via the Recall memory Delete single Print Menu y ww RECALL MEMORY RECALL MEMORY Save analysis bMem 01 1DE p1 26 01 04 16 23 Display average Date 12 12 03 2480 2 Select memory Time 15 20 30 3 gt Recall memory Delete single v Name Jerry Smith Average analysis Meas conditions v 1 26 01 04 p2 s Average analysis Meas conditions v RECALL MEMORY RECALL MEMORY 1 26 01 04 16 23 EA EE gt 3 Average analysis Meas conditions v Mem 01 1DE pDate 12 12 03 2S0 Time 15 20 30 Name Jerry Smith RECALL MEMORY 02 2 CO2 9 3 26 01 04 16 23 An 1 25 wecf mee Tf 190 1C ER E AA Ta 15 4C DAverage analysis AT 174 7C Meas conditions Y RifO2 Mem 01 A MH 1 26 01 04 16 23 EE EE aa ES BEEF Average analysis pMeas conditions F RECALL MEMORY Average analysis Meas conditions gt Draft v RECALL MEMORY a 3 Average analysis Meas conditions Draft gt Smoke v RECALL MEMORY a Average analysis Meas conditions Draft Smoke Ambient CO NO MEAS CONDITIONS Natural gas Altitude 0 m R H air 50 Jerry Smith RECALL DRAFT O 12nra T esterna RECALL SMORE WARNING Reguested data are not available AMBIENT CO NO CO Orem NO Orem
51. ot been AUTOZERO PUMP performed the pump wero cannot be switched on Use the EDIT TEXT function as follows Using the A q N cursor keys go to the box that corresponds to the letter or number required to form the desired word and press to confirm When PS have finished striking in the desired text still using the cursor keys go to to confirm the entered data or to BS exit without saving and press the relat or o button The task is done o If you wish to modify a letter or a whole line all you need to do is position the cursor in front of the letter to be cancelled by means of the cursor keys in the first row of controls At this point go to the second row of controls and press the Esc key on the keypad In this way the letter preceding the cursor can be cancelled after which the desired text can be entered or the user can confirm and exit CONFIGURATION REPORT HEADER a Time Date Alarms Autozero Pump Operator Report header setup REPORT HEADER 1 E Instruments gt 2 REPORT HEADER 1 1E Instruments 2 Philadelphia REPORT HEADER 1 E Instruments 2 Philadelphia PA 3 T 215 750 1212 TEKT EDITING gt es 4 9 lt gt F Msze 0 YZ _ A BCDEFGHI Yz I a bedefghi TEXT EDITING Philadelphia PA gt es 4 oe ess 0 YZ _ A BCDEFGHI Yz I t a bedefghi gt es 4 9 lt gt 7 es a 0 YZ _ A BCDEFGHI Yz I t a bedefghi TEXT EDITING gt es 4 9
52. perating at a constant temperature that has been on for at least 30 minutes and has completed pressure zeroing 1 The maximum CO value displayed depends on the type of fuel 2 Measurements possible only with the model comprising the NO nitrogen oxide probe 3 The field of operation of probes may be more restricted 4 Stated precision includes error of the external sensor RTD Pt100 class A DIN 43760 1980 5 Stated precision includes error of the external sensor thermocouple type K class 1 IEC584 6 Pressures greater than 750 hPa may permanently damage sensors or impair their characteristics 3 0 USING THE COMBUSTION ANALYZER 3 1 Preliminary operations Remove the instrument from its packing and check it for damage Make sure that the content corresponds to the items ordered If signs of tampering or damage are noticed notify the E INSTRUMENTS Service Center or distributor immediately and keep the original packing A label at the rear of the analyzer bears the serial number This serial number should always be stated when requesting technical assistance spare parts or clarification on the product or its use E Instruments maintains an updated database for each and every instrument Before using the instrument for the first time it is recommended to charge the battery for 12 hours with the instrument turned off 3 2 Power supply The instrument contains a high capacity Ni MH rechargeable battery The battery feeds the i
53. ponds to the Center of the exhaust pipe For greater positioning accuracy the user may insert the probe gradually into the pipe until the highest temperature is read The exhaust pipe must be inspected before carrying out the test so as to ensure that no constrictions or losses are present in the piping or stack 4 11 3 Flue Gas Analysis After the sample probe has been inserted in the stack and the combustion air temperature probe if used has been inserted in the relative sample manifold if the instrument has not been configured during auto calibration the following data must be configured Memory use this submenu to define the memory in which the test data and client details are to be stored Fuel the user will be asked to define the type of fuel used by the plant Operator this is where the name of the test operator can be entered Mode by entering this submenu the user can determine the analysis mode manual or automatic If automatic mode is chosen the reading duration of each and every test must be set besides the printing mode manual or automatic When flue gas analysis begins the instrument will perform and memorize the three tests automatically at the respective intervals set at least 120 sec according to UNI 10389 At the end of each test the instrument will emit an audible alarm one beep after the first test two beeps after the second test and three beeps after the third test At this point when all
54. pressure draft efficiency and excess air 2200 Dual sensor combustion analyzer O CO Upgradeable to three sensors with memory amp software 2200 is used to conduct direct O and CO analyses and make additional measurements and calculations of COs air flue gas and differential temperatures pressure draft efficiency and excess air The third sensor NO NOx can be added to 2200 instantly by adding the New sensor amp simple calibration at any time 2200 NOx Kit Triple sensor combustion analyzer O CO NO with memory amp software 2200 NOx is used to conduct direct O CO and NO analyses and make additional measurements and calculations of CO and NO air flue gas and differential temperatures pressure draft efficiency and excess air All the above models are available with a solenoid valve on request The solenoid valve installed on the pneumatic circuit accelerates the electrochemical cells return to full operation in the event of exposure to excessively high concentrations of CO or NO 2 0 TECHNICAL SPECIFICATIONS 21 Technical Specifications Power supply Rechargeable battery 5 x 6V 1800 mA h elements with external charger Battery life 9 hours of continuous operation printing excluded Charging time 2 hours to recharge from 0 to 90 Printer Internal 24 column impact printer for use with ordinary paper paper roll 18 m long x 57 mm wide Printer power supply From the analyzer battery pac
55. r each sensor SENSOR TYPE POSITION SETTLING TIME 02 AAC SE 01 SI 24 hours Oxygen CO DA AAC SE 03 Orange s3 48 hours Nitrogen oxide 8 If the instrument is used before the above adjustment period has occurred the accuracy of the resulting measurements may be less than that declared Fastening screw Sensor compartment flap Fig 1 Rear view Fig 2 Sensor compartment Fig 3 Example of sensor with electrical connection Fig 4 Example of sensor with electrical connection inserted removed Polarizing block Electrical connection Fig 5 Example of rotated sensor Fig 6 Example of sensor compartment without 5 9 Replacing the battery pack To replace the battery pack proceed as follows 1 Loosen the screw on the battery cover and remove the cover 2 Slide out the battery pack 3 Remove the battery pack connector and replace the battery pack with a new one reversing the operations described above al Battery pack connector 50 5 10 Replacing the printer paper roll Remove the printer plastic door as explained in paragraph 4 13 microcontroller reset Remove the paper roll plastic door by pressing to the inner the plastic tooth pointed by the arrow The door is then removed by applying a slight force towards the bottom Insert a new printer paper roll as shown in th
56. stem is authorized to operate without restrictions or intervention Compl 30 DD piping temporarily suitable for operation when the leakage flow calculated in the reference conditions is included in the range 1 dmh lt Qrif lt 5 dm h The system is authorized to operate only for the time needed for the maintenance of the pipe in order to fix the leakage problem and in any case for no more than 30 days after the testing day Once the fixing has been completed the piping must tested again for its tightness according to the UNI 7129 standard Non compliant not suitable for operation when the leakage flow is greater than 5 dm h In this situation the measured leakage is such that the piping is not suitable for operation and must immediately placed out of order Once the leakage problem has been fixed the piping must tested again for its tightness according to the UNI 7129 standard TcK Temperature The user can measure the temperatures within the range specified in the technical specifications e g plant delivery temperature by using an OPTIONAL Type K thermocouple contact probe connected to the TcK input Pt100 Temperature The ambient temperature can be measured within the range specified in the technical specifications by connecting the remote air temperature probe provided with the instrument to the Pt100 input 31 4 8 1 Flow Chart Readings Menu Activates the Smoke Menu MEASUREMENTS gt Smoke Ambient CO NO Mea
57. sts the display contrast gt Natural gas L P G Diesel oil Fuel oil Methane G20 v ww DP gt 1 Jerry Smith 2 John Doe 3 Jane Doe vvvo Duration 120 s Print manual 38 When depressed for at least 2 seconds turns the instrument on Rey analyzer parameters can be configured during auto calibration The pP and eys respectively confirm an cancel any ffected modifications and take the user back to the previous level menu In the Select menus the cursor indicates the active value In this phase one can either select the test operator and or change the name displayed refer to Configure Menu Setup the report printing selecting the number of copies and the type of report to print At this point the user can select the analysis mode automatic or manual if automatic mode is chosen the test time and printout format must also be set Natural gas The Configure Analysis Menu can also be accessed Mario Rossi full after auto calibration is complete manual 4 10 Flow Chart Flue Gas Analysis When depressed for at least 2 seconds turns the instrument on A Adjusts the display contrast d O Ag play v Do not insert the gas probe in the chimney Or automatically after 10 seconds za a Date Select the memory wherein to store the acquired data ime Name Autozero 25 Select the fuel of the plant being tested Bat 94 2 Time 11 3 D
58. sure 2 int setup Pressure Measure 3 feed Tightness test i test TC K temperature Average value 2 Measure 1 report MEASUREMENTS AMBIENT CO NO k report gt Ambient CO NO int setup Pressure feed Tightness test i test TC K temperature v In the Smoke menu the user can input the smoke value The values entered with the arrow keys can be associated with the ongoing analysis through the j o key or printed with the Print menu The CO NO ambient gas gives a measurement indicating the safety of the environment in which the operator is working The concentration values can be associated to the ongoing analysi MBth the lt 7 Rey or printed on a ticket through Tne Print menu MEASUREMENTS PRESSURE PRESSURE Smoke Ambient CO NO gt Pressure Tightness test TC K temperature v O OOhPa O OOhPa MEASUREMENTS Smoke Ambient CO NO Pressure gt Tightness test TC K temperature MEASUREMENTS TC K TEMPERATURE Ambient CO NO o Pressure 1 90 0 F Tightness test gt TC K temperature v MEASUREMENTS A Ambient CO NO Pressure Tightness test TC K temperature gt Pt100 temperature Pt100 97 5 F TEMPERATURE 32 PRESSURE See the TIGHTNESS TEST flow chart next page Tightness test flow chart according to standards UNI 7129 and UNI 11137 TIGHTNESS TEST UNI 7129 STANDARD gt New piping gt Start test Existing piping Stabilization STABILIZATIO
59. t the water separator for a simultaneous draft measurement and flue gas analysis The positive inp p is used for measurement of a differential pressure Fuel types The instrument has been programmed with the technical characteristics that are typical of 10 common fuels Smoke measurements It is possible to enter the smoke values measured according to the Smoke scale The instrument will calculate the average and print the results in the analysis report An external pump available as an optional must be used to effect this measurement Pressure decay test The instrument can perform the tightness test of a piping according to the Italian standards UNI 7129 and UNI 11137 For this test the same pressure sensor used is the same as that for the draft test Calibration certificate The instrument is calibrated by comparing to specimen samples provided by a Metrology Lab certified periodically by internationally recognised laboratories A calibration certificate is provided with each and every instrument where every parameter is accompanied by the relevant nominal value measured value permissible error tolerances and measured error Electromagnetic compatibility The instrument was designed to comply with Council Directive 89 336 EEC governing electromagnetic compatibility 23 Measurement and Accuracy Ranges MEASUREMENT SENSOR RANGE RESOLUTION ACCURACY O Electrochemical 0 25 vol 0 1 vol
60. tandard to be defined Somebody proposes 5000 Pa Note The 1100 2200 analyzers allow the user to perform the tightness test even with a combustible gas different from the supply gas Anyway the reference standard does not provide a reference pressure in this situation so the reference pressure is taken like test gas is the same Test result should be considered only indicative The 1100 2200 analyzers allow the operator to customize the stabilization phase through the following parameter in the stabilization menu WAIT TIME the stabilization phase duration can be set in the 1 to 99 minute range As the UNI 11137 standard does not prescribe any stabilization duration the factory setting for this value is borrowed from the UNI 7129 standard which requires a minimum stabilization time of 15 minutes The waiting can be interrupted any time by pressing the key even in case the interval has not fully elapsed The tightness test performed according to the UNI 11137 standard requires the input of some data regarding the piping system and the test conditions as described in the following PIPING VOLUME An accurate tightness test performed according to the UNI 11137 standard requires the user to know the piping volume Because this data if often unavailable The 1100 2200 analyzers split the test from the beginning into two different paths the first is adequate for piping having volume smaller than 25 dm liters this is the most usual situatio
61. the combustion analysis measurement values and information without any header comments or blank lines for operator comments Total Is arranged with the complete layout of the average analysis followed by the single analysis measurements report Advance paper Feeds paper in the printer this function is most useful when replacing the paper roll in the printer Trial print Prints a graphical alphanumeric test ticket for a complete check of the printer operation 23 4 5 1 Flow Chart Print Menu tightness test results report setup Paper feed test Enables the Print Menu Allows the user to print the combustion analysis data on a paper ticket which reports the measurement values The printed values are those shown on the display when the menu is enabled This menu can be used for combustion analysis even when recalled from the memory for draft smoke ambient gas and for PRINT SETUP report setup feed test PRINT REPORT gt Print report Analysis running Print setup Model smoke Paper feed Print test PRINT REPORT Memory Analysis Model PRINT REPORT Memory 01 Analysis average full Several copies of the test ticket can be printed choosing among different layouts according to the information included According to the values shown on the display when the menu is activated and the selected ticket layout the user can choose among different models In the examples are reported the cas
62. trogen oxides concentration in flue gases for 2200 analyzers only Percentage of heat lost through the stack Efficiency This is the burner efficiency calculated according to the UNI 10389 standard as ratio between the conventional heating power and the burner heating power Among the combustion losses only the sensible heat lost with the flue gases is taken into account thus neglecting the radiation losses and incomplete combustion losses The sensible efficiency value is to be compared against the minimum efficiency stated for the heating systems performances n Zoom Menu This menu can only be accessed when the analysis screen is displayed This key is used to view the test data on a complete list or multi page list or to zoom in on displayed text for better reading 25 4 6 2 Flow Chart Measure Menu Activates the Measure Menu d For each of the screens until now shown the display in O reference mode Ref O is highlighted can be activated by pressing the y key By pressing the Measure key once more and starting from any of the above screens the user may proceed as follows ANALYSIS SETUP SELECT MEMORY a gt Natural gas Jerry Smith full Select the memory wherein to store the acquired data manual 26 gt Natural gas L P G Select the fuel of the plant being tested Methane v OPERATOR ID gt 1 Jerry Smith Y Y 2 John Doe 3 Jane
63. uctory screen will appear After a couple of moments the instrument will zero itself and will state that the sample probe should not be inserted in the stack It is important that the sample probe is not inside the stack since during auto calibration the instrument draws fresh air from the environment and detects the zero value of the O CO and NO sensors the details of which are then memorized and used for reference during the analysis It is equally important that this phase is performed in a fresh air environment The pressure sensor is also zeroed during auto calibration 4 11 2 Inserting the probe inside the stack When auto calibration is complete the instrument will instruct the user to insert the sample probe that has been previously connected to the relative input on the instrument and the analysis screen will appear automatically In order for the probe to be inserted at the right point within the stack its distance from the boiler has to be twice the diameter of the stack pipe itself or if this is not possible must comply with the boiler manufacturer s instructions In order to position the probe correctly a reliable support must be provided by drilling a 13 16 mm hole in the manifold unless already present and screwing in the positioning cone provided with the probe in this way no air is drawn from the outside during sampling The screw on the cone allows the probe to be stopped at the right measuring depth this usually corres

E Instruments BTU1100 Combustion Gas Analyzer User Manual

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